Decomposing method and apparatus for subhalide distillation



Feb' 8, 1966 N. w. F. PHILLIPS ETAL 3,234,013

DECOMPOSING METHOD AND APPARATUS FOR SUBHALIDE DISTILLATION Filed Aug. 6, 1963 United States Patent O 3,234,013 DECMPOSING METHOD AND APPARATUS FR SUBHALIDE DSTILLATIN Norman Vv". F. Phillips and Frederick William Southam,

Arvida, Quebec, Canada, assignors to Aluminium Laloratories Limited, Montreal, Quebec, Canada, a corporation of Canada Filed Aug. 6, 1963, Ser. No. 300,364

18 Claims. (Cl. 75-68) This application is a continuation-in-part of our cepending application Serial No. 236,353, led November 8, 1962, now abandoned for Decomposing Method and Apparatus for Subhalide Distillation.

This invention relates to the so-called subhalide distill-ation of aluminum, and is particularly directed to procedure and apparatus vfor decomposing gaseous aluminum subhalide to obtain a purified or refinedk aluminum product.

The recovery of purified aluminum metal from impure aluminum-containing metallic material by subhalide distillation involves treating the material to produce a subhalide of aluminum in gaseous state, and decomposing the subhalide gas in a reverse chemical reaction which yields relatively pure aluminum metal together with a normal aluminum halide in separated or separable form. In a preferred way of carrying out this process, the impure material is heated and exposed to a iiow of aluminum trichloride gas (i.e. AlCl3) in -a suitable converter. At appropriate temperatures, ordinarily in the range of about 1000 C. and upwards, aluminum in the material reacts with the aluminum trichloride to form aluminum monochloride ygas (i.e. AlCl). This monochloride gas, usually intermixed with unreacted trichloride, is conducted from the converter to condenser apparatus (herein for convenience termed a decomposer) where it is reduced in temperature and thereby caused to decompose or dissociate into aluminum metal, desirably in molten form for ease of removal from the decomposer, and aluminum trichloride gas, which may be withdrawn from the decomposer together with the aforementioned unreacted trichloride gas and recycled to the converter for re-use therein.

Since the monochloride dissociation reaction is exothermic in character, the cooling action provided in the decomposer must be effective not only to remove heat from the gas as introduced to the decomposer but also to `absorb the heat of reaction produced as the monochloride decomposes, in order to maintain the requisite reduced temperature conditions for such dissociation. At the same time, it is important that the internal temperature of the decomposer, at least in collecting the metal, be kept above the melting point of aluminum (about 660 C.) so that the aluminum produced and accumulated in the decomposer will remain in molten state therein as desired. Thus satisfactory decomposer function requires the provision of .efficient heat removal without excessive cooling, advantageously in a manner suitable for commercial or like large-scale operation.

An important object of the present invention is to provide improved procedure and apparatus for effecting such monochloride decomposition in a facile and eiiicacious manner suitable for practice on any desired scale of operation.

To this and other ends, the present invention in a broad sense contemplates eiecting direct contact of the monochloride-containing gas, as discharged from the converter, with a molten salt which is below the temperature of the gas. Such contact may be eiiected in any of a variety of gas-liquid contacting devices such as spr-ay towers, packed beds, wetted wall columns, tray columns,

3,234,013 Patented Feb. 8, i966 ICC splash condenser or the like, e.g. providing for contact of gas and liquid in countercurrent ilow and in particular providing an extended gas-liquid contact surface. Thus, by way of example, a generally upward ow of gas from the converter (i.e. :a heated mixture of monochloride gas and unreacted trichloride gas) may be established in a decomposing region in intimate -contact with a generally downward iiow of molten salt therein. Heat exchange between the gas and salt occurs as a result of such contact; specifically, the salt cools the gas to a temperature at which the monochloride decomposes into aluminum metal and trichloride gas, and takes up the heat of reaction produced by the exothermic monochloride dissociation so as to maintain the monochloride at such temperature.

The molten salt as introduced to the decomposing region may initially be at a temperature above (usually only slightly above) or somewhat below the melting point of aluminum, but its temperature fas discharged from said region should be above the melting point of aluminum. The aluminum produced in the decomposition of the aluminum monochloride is carried with the downward ilow of molten salt to the lower portion of the decomposing region, where it collects in a molten pool. If the temperature of the salt is initially above the melting point of aluminum, the aluminum produced will be in the form of liquid droplets. If the temperature of the salt is initially below the melting point of aluminum, the aluminum produced will be in solid particulate form, which however, will melt on reaching the met-al pool. The initial temperature of the molten salt as it enters the gas contact region may be selected to suit the conditions chosen for the operation and system, a major factor being the temperature desired for the aluminum trichloride gas discharging from such region, it being understood that with countercurrent gas and liquid flows such discharge occurs in the vicinity of the ingress of molten salt. Optimum initial salt temperature can be readily determined by simple test if necessary, for any type and size of decomposer and for selected operating conditions; for instance, if it appears that undue cooling is causing the aluminum to form as a fog or smoke (as may be likely to occur should the incoming salt temperature be as low, say as 200 C.) or is causing incrustation of solid metal on surfaces, e.g. of the packing, inside the decomposer, a substantially higher inlet salt temperature should be employed, to insure washing down of metal particles or droplets. In all cases, whatever the initial temperature of the salt, it should be such that the latter is sufficiently heated, by the gas :contact and decomposing operation, to reach a temperature appreciably above the melting point of aluminum, as it lapproaches the locality where such salt collects.

As indicated, the molten salt (as well as the molten metal) collects at the lower portion of the decomposing region. However, the molten salt used is selected to have a specific |gravity substantially diiierent from that of molten aluminum, so that the aluminum and molten salt collect in discrete pools (ie. one iioating on the other) at the bottom oft the ldecomposing region and may with `facility be separately removed therefrom. Consequently, the molten salt may be removed for cooling at an external locality and recirculated to the decomposing region for re-use as the heat exchange medium, while quantities of molten aluminum are discharged, eig. periodically, as the desired puried product of suibhalide distillation. The trichloride gas produced in the dissociation reaction, together with the unreacted trichloride constituent of the introduced gas from the converter, is withdrawn from an upper locality in the decomposing region.

v Very advantageously, the molten salt employed in the present inivention may be provided by a chemically stable,

low meltin-g point molten salt mixture including as one l constituent a substantial proportion of aluminum trichloride.

heat exchange occurring in the decomposing region evaporates a portion olf the aluminum trichloridev contained in the mixture. In this situation, the .initial excess heat of the gas from the converter and the heat produced by monochloride dissociation are taken up not only in rais-ing the temperature of the molten salt but also in part as heat of evaporation of aluminum trichloride, with some ad- Vantage in heat removal action. The trichloride gas evaporated from -the salt mixture is removed 4from the decomposing region in admixture with the trichloride gas otherwise produced in or introduced to the latter region as explained above.

In such case, the molten salt mixture collecting at the bottom of the decomposing region .will be somewhat lean in aluminum trichloride, owing to the evaporationY result- Ithe trichloride gas Withdrawn from the ,decomposing region, e.g. in a suitablesplash condenser to which such portion of lthe trichloride gas is diverted, underV conditions suc-h that the trichloride gas is conden'sedor asbsorbed in .the salt mixture to augment the trichloride" content of the mixture. The remainder of the trichloride gas from the decomposing region may be recycled to the converter-for re-use therein.

Such condensation o-f a portion ofthe trichloride gas in the salt mixture has the further advantage of removing impurities from the recirculat-ing stream of trichloride gas. The gas discharged yfrom the-converter contains gaseous contaminants or impurities such as hydrogen or methane,

produced in the converter, which pass through the decomposing region and tend to build up in the stream of trichloride gas circulating between the decomposer .and the converter, undesirably diluting the trichloride gas, 4as this When a molten salt mixture of this character is used, conditions may be selected, if desired, so that the .30 by exposing the cooled lean salt mixture to a portion of gas is repeatedly recycled through the subhalideldistillation system.v However, a portion of these impurities accompanies the portion of trichloride gas-diverted for condensa-tion in the salt mixture according tothe procedureV When the trichloride con/denses in the salt mixture, the contaminants remain in gaseous fon-rn describedv above.

`and may readily be removed from the system; the trichlo ride re-evaporated from'the salt mixture in the decomposing reg-ion is consequently puried. In such manner,

therefore, the buildup of impurities in the circulating trichloride flow can Ibe effectively controlled.

Further features and advantages of the invention will I beapparent from the detailed description herein-below set forth, together with the accompanying drawing, in which:

FIG. 1 illustrates schematically a subhalide'distillation system incorporating the apparatus of the presen-t invention in one particular embodiment; and

FIG. 2 is a diagram of a part of a system thatis otherwise similar to FIG. 1, showing a modied embodiment duced to the chamber. through an inlet shown as a hopper 1I opening at the -top of the: converter, and is withdrawn fromthe chamber (after treatment therein to eifect'removal of aluminum) through an outlet at the lower end of the converter, repre-sented as a conduitlZ. The converter also includes means for passing an electric current .through `the mass of material in the .chamber to effect electrical resistance heating of the material; such means are illustrated as a pair of vertically spaced electrodes 14, `15, which may be of annular or` other conguration'arrangedfor contact With the materialin the chamber, and which lare connected lto a suitable power source :16.l A gas inlet conduit 18 opening at a lower region orf the converter chamber andra gas outlet conduit19 arranged for withdravva'l of gas from an upper locality in the chamber are. also provided. It will be appreciated that the foregoing. Y

structures are herein shown and described in highly sin1pli tied form and lbymvay of illustration only, to exemplify ,one

type of converter with'iwhich Vthe present invention ymayl be associated? In the operation of suchaconverter, the@ internal con' verter chamber isy substantially filled withk the lumpsV and granules of impurematerial to be treated, san .example of suchmaterial being the crude alloy'produc'edfby the direct reduction .of bauxite. This material in the chamber is maintained, as bythe .aforementioned .electrical resistance heating, ata temperature e,g.I in the rangef of;

about1l000 C; and upwards;y Heated'aluminum trichloride gas', introduced to the chamber in a continuousV flow through 'the conduit 13,` passes upwardly-through,` t-he chamber, permeating theV in terstices of the heatedy Under the Vconditions of elevated'temperature maintained inl the chamber this trichloride gas. reactsjvvith aluminum mass of crude alloy V or other ymaterial therein.

in the alloyto form aluminum monochloride' gas. Def.

sirably the converter operation is carried forward in an.

essentially continuous -mannerg thus, successive :increments of unreacted alloyrrfrare Iintroducedy through the.

hopper 1l to the top of the mass in the converter chamber, and advanced downwardly i through the chamber,

being progressivelyfdrepleted 'of aluminum by contacty The alloy commodate fresh increments of `unreacted alloyat the;

upper end of the chamber.

The monochloridei gasl produced in the converter, to,

gether'with unreacted trichloride gas, is Withdrawn (eg. continuously) from the converter chamber through the gasoutlet conduit 19.l As thus discharged,.they monof chloride-trichloride gas mixtureis at a temperatureY .ap-Y proximating the converter chamber temperature, i.e. in the range of about 1000 C. and upwards. This gas is delivered by the conduit 19 to a decomposer, generallyV designated 20.` i i Inaccordance with 'the' present invention, the decomposer 20 comprises a steel vesse1'2l having a refractory lining 23 composed of material resistant to deteriorationV by the gases.A and liquids to which itis exposed at :the f temperatures involved.V Thelining 23 defines an elon gate, Vupright internal decomposing chamber'i24 `separated into an upper tower portion 26 and a lower sump.

terial, such as .alumina lumps, which is inertwith respect to the gasses and other substances to which it is exposed; this packing, as shown, is `supported on the -perforate j plate 2S.

' A conduit 3), adaptedrto convey a molten` salt tothe decomposing. chamber, .opens downwardly through the top of the tower 26 in such manner as to deliver the molten salt to the upper surface of the packing 29. Desirably this molten salt is sprayed more or less evenly over the surface of the packing so that it passes downwardly through the packing in a thoroughly dispersed fashion flowing over the individual lumps or elements of the packing. The conduit 19 conveying the heated monochloride-trichloride gas mixture from the converter opens in the upper part of the sump 27, i.e. just below the perforate plate 28, such that the gas delivered by the conduit 19 will pass upwardly through the perforate plate and thence through the packing countercurrent to the aforementioned flow of molten salt. The perfonate plate serves to distribute the flow of gas evenly through the packing.

In this way effective gas-liquid contact between the upward ow of gas from the converter and the downward now of molten salt from the conduit is effected in the tower portion of the decomposer and specifically in the packing 29. That is to say, the tower 26 and packing 29 function as a conventional packed tower in providing thorough gas-liquid contact. The downward ow of liquid is spread over the individual packing elements providing an extended contact surface area so that the dispersed upward ow of gas through the packing is thoroughly exposed to the salt.

The decomposer 2t? in the form shown is adapted for use With a molten salt mixture containing a substantial proportion of aluminum trichloride as one constituent thereof and having a specific gravity lower than that of molten aluminum. In the operation of the decomposer, this molten salt mixture is delivered to the top of the tower portion 26 through the conduit 3i) at a suitable temperature which may be selected as indicated hereinabove and which is preferably quite substantially below the temperature of the gas introduced through the conduit 19. The gas-liquid contact effected in the packing 29 between the countercurrent tiows of gas and molten salt mixture is effective to cool the introduced gas from the converter by transfer of heat therefrom to the molten salt. This heat is taken up by the molten sa'lt both in raising the temperature of the salt and also, in the specic process assumed for FIG. 1, in evaporating aluminum trichloride gas from the salt. As a result of such cooling, the monochloride in the gas is caused to dissociate into aluminum metal and aluminum trichloride gas; dependent on the temperature of the salt, the metal is in molten form, or is in particulate solid form, becoming molten as it is carried toward, or when it reaches, the pool at the bottom.

Thus the produced aluminum metal is carried with the molten salt down through the packing 29, and thence through the perforate plate 28 into the sump, where the molten aluminum collects in a pool 32 at the lower end of the sump and the molten salt collects in a separate pool 33 which iioats on the pool of molten aluminum because of its lower specific gravity. Means shown as a conduit 35 opening downwardly from the lower end of the sump are provided for effectingy withdrawal of molten aluminum from the sump, and means shown as a conduit 37 opening through the side of the sump above the level of the molten aluminum pool 32 tare provided for separately withdrawing molten salt from the sump. An outlet is also provided for the aluminum tricloride gas produced in or introduced to the decomposing chamber, such outlet being illustrated as a conduit 39 opening at the upper extremity of the tower 26.

The system shown further includes an absorber comprising a vessel 42 to which molten salt from the pool 33 in the decomposer sump is delivered by the conduit 37. The absorber vessel is adapted to contain a pool 43 of the molten salt thus delivered, and includes cooling means shown as a pipe 45 disclosed in the vessel to be immersed in the pool of molten salt 43 and adapted to convey a circulating llow of suitable coolant liquid such 6 as water from an external supply (not shown). As will be understood, with such cooling means heat from the molten Salt is transferred to the circulating flow of coolant and the temperature of the molten salt is thereby reduced.

Due to the evaporation of aluminum trichloride from the molten salt in the decomposer, the molten salt delivered to the absorber vessel 42 through the conduit 37 from the pool 33 in the decomposer is Vlean in aluminum trichloride. The absorber is arranged to augment the proportion of aluminum trichloride in the molten salt introduced thereto, and is specifically adapted to cause a portion of the .aluminum trichloride gas discharged kfrom the decomposer through the conduit 39 to be condensed and absorbed in the pool of lean molten salt mixture 43. This gas is led to the absorber through a conduit 47, opening downwardly into the absorber vessel '42 through the roof of the vessel on one side thereof, and communicating with the gas conduit 39 in such manner as to divert to the vessel a portion of the trichloride gas flowing through the conduit 39. The vessel 42 `also includes a gas dischar-ge outlet 49 opening through the roof of the vessel on the side thereof opposite the conduit 47, and a vertical baffle 5t? extending downwardly from the roof of the vessel intermediate the conduit 47 and the gas outlet 49 and terminating above `the level of molten salt in the pool 43. The baille '50 is arranged to permit passage of gas in the vessel, i.e. from the conduit 47 to the outlet 49, only through the restricted space between the lower edge of the baie and the surface of the molten salt pool 43. In addition, rotary impeller blades 52, l53, driven by appropriate means (not shown) and adapted to provide splash condenser action in the vessel, extend downwardly through the vessel 42 and into the pool of molten salt on respectively opposite sides of the bale 50.

With this arrangement of elements, aluminum trichloride gas introduced to the absorber vessel 42 through the conduit 47 is exposed to a spray of molten salt mixture provided by rotation of `the impeller blade 52 so as to afford an extended contact surface area `for absorption of the gas in the salt mixture. Such gas as is not initially absorbed in the salt mixture passes under the baifle 50 and thence into Ithe second region of the absorber vessel where it is again exposed to Ia spray of molten salt mixture provided by rotation of the impeller blade y53. In this manner, substantially complete absorption of the aluminum trichloride gas in the molten salt mixture is effected, enriching the trichloride content of the mixture as desired. Gaseous constituents other than aluminum trichloride introduced through the conduit 47, e.g. impurities in the aluminum trichloride gas flow, remain uncondensed and are discharged from the absorber vessel through the outlet 49.

The conduit 3d through which molten salt is delivered to the decomposer communicates with the absorber vessel at a locality beneath the level of the molten salt pool therein and on the opposite side of the vessel yfrom the opening of the conduit 37, such that lean salt entering the vessel '42 from the decomposer traverses the vessel in a direction substantially countercurrent to the iow of aluminum trichloride vgas therein, and is t-hen withdrawn from the vessel, enriched in aluminum chloride by the aforementioned absorption action in the vessel, through the -conduit 30. A suitable pump 55 of conventional character, connected in the conduit 30, advances the enriched salt mixture from the `absorber vessel 42 back to the decomposer for re-use therein as the heat exchange medium. In other Iwords, then, the molten sait mixture is circulated e.g. in a substantial-ly continuous manner between the decomposer and the absorber vessel; in the decomposer, aluminum trichloride evaporates from the salt mixture due to the heat exchange action therein and the salt mixture is also heated to some extent, while in the absorber the salt mixture is cooled and the aluminum trichloride content replenished (desirably to restore the initial proportional composition of the mixture), beforel the mixture is returned to the decomposer.

That portion of the Valuminum trichloride gas with drawn -from the decomposer which is not diverted from the conduit 39 to the absorber 42 is .advantageously recycled to the converter for re-use therein to provide the continuous ow of aluminum trichloride gas in the ance of the decomposing process of the present invention with the system of FIG. 1 may be readily understood:

Aluminum trichloride-containing molten salt mixture .at

an appropriate temperature is advanced continuously4 through the conduit 30, underthe iniuence of the pump `55, to the top of the decomposer tower 26, where it is dispersed in a downwardly directed spray over the surface of the tower 'packing 29.V Heated `gas from therconverter (containing aluminum monochl-oride mixed with unreacted .alu-minum trichloride),ladvanced through the conduit 19 to a locality in the Vdecomposer beneath the perforate 28, flows upwardly through the plate and thence through the packing 29. Asone example, -the monochloride-containing gas may be delivered into the decomposer at a temperature of 1220 C. and at approximately atmospheric`- pressure. heated gas from the converter and the moltensalt'mixture is effected over an extended contact surface area provided by the packing, i.e. as the molten salt and `gas pass in dispersed counter-current flows over and -between the packing elements or lumps.

Heat exchange occurs between the gas and salt incident to such contact, cooling the gas to atemperature atwhichl the monochloride decomposes into aluminum metal and aluminum trichloride gas. The heat of reaction produced by this monochloride dissociation is also taken up by the salt mixture in the packing so as to maintain the monochloride at the desired reduced temperature for decomposition. As a result of such heat transfer, the temperature of the molten salt is increased and under the condi' tions assumed for FIG. 1, aluminum trichloride gas is also evaporated from the salt mixture, i.e. some of the heat is absorbed as heat of evaporation of @aluminum trichloride, providing very efficient heat removal. Y

The aluminum metal produced by the monochloride decomposition passes downwardly with the flow of molten salt mixture, through the packing 2.9 and the perforations of the plate 2S to the sump 27. The molten aluminum,

which has the higher speciiiclgr-avity of the two liquids,` collects in a pool at the bottom of the sump; the molten salt mixture collects in a discrete pool oating on the molten aluminum in the sump. This molten salt is somewhat elevated in temperature and to some extent reduced in aluminum trichloride content, as compared with the salt introduced to the top of the tower 26, owing to the `heat exchange and evaporation of aluminum trichloride occuring as it passes, in contact with the:V gas:

from the converter, downwardly through the packing 29.

The aluminum trichloride gas produced by the monochloride. :decomposition and byV evaporation from the molten salt in the decomposer, together with the ,unreacted-aluminum` trichloridegas from the converter in-V troduced with 'the monochloride gas through the `conduit 19, is continuously withdrawn from theY decomposerr through the conduit 39 at the top of the tower. Desirably the length of traverse 'of the gas from the converter through the Lpacking 29 and the heat exchange conditions maintained in the ltower are such as to eitect substantiallyv complete decomposition of the monochloride gas passing therethrough, and hence the g-as withdrawn from Gas-liquid contact between this the top of the tower throughthe, conduit 39 is primarily only aluminum trichloride together with such gaseous contaminants or impurities (e.g. hydrogen,` and some-` times methane or others) as may be produced in the converter and carried in the iiow of gas therefrom.

The purified 'molten aluminum metaly 'collected nathe pool 32 (which remains molten because the coolant salt` mixture is collected and removed from the decomposer at a *temperaturel above the melting pointof aluminum) is withdrawn therefrom from time :to time, constituting the puried metallic aluminum product of thesubhalide num from the pool 32 islcontrolledV to maintain the level of the pool 32'below the locality ofthe conduit`37, so.

that no molten aluminum is "carried with the salt mixture to the absorber, and also to `maintain the level ofV the salttpool 33 somewhat below the localityof the conduit 19, afford a region between'the salt pool 33andthe plateZSthrough which the incoming gastrom the rcon-` verter can .circulate foreven upward dispersion through the plate 28.1`

The trichloride-lean molten salt mixtureV flowing fromA the decomposerthroughthey conduit 37 .passes into and through theabsorber vesselg42, lwhere .itris cooled as by the cooling pip'er45 'and exposed to afportion ,of thealuminum trichlorideigas discharged from the decomposer through-,theconduit 39. Contact of'theigas and the molten Vsalt inthe vessel 42 is promoted bythe splash f condenser action of the rotary gimpeller blades 52, 53; as a resultof such contact, the aluminum trichloride ofthe gas is substantiallygentirely condensed and'absorbedfin num trichloride.` mixture is then advanced from the absorber vesselV 42 through the conduit 30k by the action ofthe pump 5,5,` back to the top .of the tower 26 rwhere it is again sprayed.

As previously mentionedthe gaseous contaminants orI impurities admixedwith the ,trichloride .gas Vdiverted to the absorber vessel. 42 from: themain.. trichloride ow.

in the conduit 39 are discharged from'the absorber vesselV .through the .outlet 49 and thus;` removed from the system.. In other words, there .is a continuous extraction of the such impurities.Y in the absorber. yessel, which serves to counteractthe continuous productionV of such.. impuritiesin the converterV and thereby to control or limitV theV buildup of diluentcontaminants in.thefrecirculating flow of trichloride gas.

Very advantageouslthe, *amountl of trichloride restored to the salt mixture inthe absorber vessell42isl equal to the amount of trichloride evaporated from the salt mixture in the decomposer, suchthat the proportion` ate composition of the trichloridelcontaining salt mixture introducedto the top. of .the towerZe. remains constant during the operation of the decomposer.

ture in the decomposer. The remainder yof the `trichloride gas flowing through "the conduit 391is advanced by the pump 58 'through the heaterA 60 and thence .through the conduit'lS tothe converter 10. ,As will be appreciated, the proportion -Vof the trichloride. iiowfthus returned `to the converter isequal or approximately equal,V to the propoli-1 tion of the trichloride ilow through the conduit 39'con- .i stituting'unreacted trichloride gas-.advanced yto the de-Y` composer. fromthek converter .in admixture with'mono-y chloride,together with the trichloride' product of mono chloride dissociation in 'the decomposer. In'such manner, a substantially constant flow of trichloride gas is returned to the converter to provide the desired continuous ilow of trichloride gas therethrough. 'f

The molten salt employed in the foregoing process may comprise a mixture of aluminum trichloride and one or more alkali metal chlorides or alkaline earth metal chlorides, reference to alkaline earth metals herein being meant to include magnesium as well as calcium and the metals specifically classed with calcium in this category of the periodic table. Specifically, the constituent salts are selected to provide a molten salt mixture of high chemical stability, low melting point, and specific gravity lower than that of molten aluminum. Thus, for example, the molten salt used may consist of a mixture of aluminum trichloride and sodium chloride containing 50 to 5l mole percent (or slightly more) of aluminum trichloride as introduced to the decomposer. Such a mixture is particularly advantageous from the standpoint of economy due to the low cost of the constituent salts.

The following specific example will serve further to illustrate the performance of the process embraced in the present invention with apparatus of the character described:

A mixture of aluminum trichloride gas and aluminum monochloride gas discharged from a subhalide converter at a temperature above 10G0 C., for instance as specified above, and in such proportions as to yield one pound of purified aluminum metal for each 11 pounds of gas is introduced to the decomposer Ztl through the conduit 19 in a continuous flow. Simultaneously, a molten salt mixture containing 70.5% aluminum trichloride by weight (51.2 mole percent) and 29.5% sodium chloride by weight is introduced to the top of the tower 26 through the conduit 30 in a continuous liow at an initial temperature of 675 C., and at a rate of 131.5 pounds of salt mixture per pound of purified aluminum metal produced in the decomposer (i.e., 131.5 pounds of salt mixture for each l1 pounds of gas delivered from the converter through the conduit 19). Gas-liquid contact in the tower 26 between the upwardly flowing gas mixture from the converter and the downwardly owing molten salt mixture from the conduit 30 cools the gas, effecting decomposition of the monochloride to produce molten aluminum Vmetal and evaporating 3.7 pounds of aluminum trichloride from the molten salt mixture for each pound of aluminum produced. The molten salt mixture, together with the molten aluminum produced by the monochloride decomposition, flows downwardly through the decomposer to 4collect in the sump 27. As thus collected in the sump (i.e. after passage through the tower 26) the molten salt 'contains 69.8% aluminum trichloride by weight (50.2 mole percent) and 30.2% sodium chloride by weight and is at a temperature of 750 C. 127.8 pounds of such trichloride-lean salt 'mixture collect in the sump and are passed to the absorber vessel 42 for each pound of aluminum produced in the decomposer. 13.7 pounds of aluminum trichloride gas are discharged from the decomposer through the conduit 39 per pound of aluminum produced, and of this flow 3.7 pounds of aluminum trichloride gas (i.e., a proportion equal to the proportion of aluminum trichloride evaporated from the molten salt mixture inthe decomposer) are diverted through the conduit 47 to the absorber vessel 42. The remainder of the trichloride ow, viz., l pounds of trichloride gas per pound of aluminum produced in the decomposer,is returned through the conduit 39, pump 58, heater 6l), and conduit 18 to the converter. In the absorber vessel 42, the aluminum trichloride gas advanced thereto is condensed and absorbed in the lean molten salt mixture, so

that the molten salt mixture leaving the vessel 42 convsame as in FIG. 1 and therefore not shown again. a conduit 72, which may include a pump 73, molten salt 'l0 vanced to the absorber vessel 42, 131.5 pounds of this enriched salt mixture are withdrawn through the conduit 30.

As will be appreciated, the quantitative values set forth in the foregoing example are to be taken as exemplary of the relative proportions of liquids and gases involved in the performance of the process, i.e., expressed in terms of pounds of material used or produced per pound of purified aluminum metal produced in the decomposer. Under the specific conditions given for FIG. l, approximately 15% of the heat removal is due to the evaporation of aluminum trichloride in the decomposer, a proportion which may be readily varied by varying the composition of the molten salt feed into the top of the decomposer.

In practice, the present process may be carried out on any desired scale of operation with equally good results; since the heat removal effected in the decomposer is provided by intimate contact between gas and molten salt, any given ow of gas from the converter may be handled in the decomposer by providing sutiicient molten salt at the appropriate temperature and gas-liquid contact means of appropriate dimension and character. Temperature conditions as discussed hereinabove have for some purposes been related to the melting point of pure aluminum, approximately 660 C., but it will be understood that in some cases the produced aluminum metal may in fact be an alloy, for example an alloy containing some manganese. In the latter situation, the alloy (which can still be considered as purified, relative to the crude material from which its dissociated halides were originally derived) will have a somewhat lower melting point than the above figure; hence references herein simply to the melting point of aluminum will generally be taken as embracing values for similarly produced alloys, as of the nature stated.

FIG. 2 illustrates a modied system, adapted for a mode of procedure wherein there is no evaporation from the molten salt in the decomposer, heat being removed essentially wholly by absorption in the salt mixture. Here the decomposer 76 may be similar to the device 2@ of FIG. l, receiving a gaseous mixture of aluminum monochloride and trichloride through conduit 19a from the Converter and discharging gaseous aluminum trichloride through conduit 39a for recirculation, the converter and other parts of the main gas circulation system being the From mixture is supplied to the decomposer "itl for contact with the gas therein, and is withdrawn at a higher temperature, through a conduit 74, to traverse a cooler and return to the line 72. The cooler 75 may be of any suitable character, being simply shown as having cooling means 76 which is in heat exchange relation with the salt and which 'may be supplied with coolant fluid from an outside source `tions may be achieved by appropriate adjustment of the valves 78 and 8i). Aluminum metal, in molten state, produced by decomposition of the monochloride, is with- 'drawn at 35, as in FIG. l.

A specific example of a process performed with the system of FIG. 2 involving no evaporation in the decomposer is as follows: For each 11 pounds of gas consisting of aluminum monochloride and aluminum trichloride supplied at 19a from the converter in proportions to yield one pound of pure molten aluminum (as at 35) by essentially complete decomposition of the monochloride, 152 pounds of molten salt mixture are circulated as heat-removing agent through the decomposer 70, such being a liquid mixture of aluminum trichloride and sodium chloride containing 50.2 mole percent aluminum trichloride. Entering the decomposer 70 at 72, the molten salt has a temperature of 675 C.; heated by cooling the gas and by yelfecting kdecomposition of the aluminum monochloride, 'the salty (having the same compositionas statedlabove) leaves the decomposer (conduit 74) Vat 750 C., and on traversing the cooler, is restored to the temperature ,of 675 C. for recirculation by the pump ,7.3., As will be seen, there is no evaporation of aluminum trichlorideffrom the molten salt, so that from each ll pounds of input gas, pounds of gaseous trichloride is discharged from the decomposer at 39a, for recirculation (or other appropriate handling) in the main system.

While in the foregoing description specificV reference has been made to the use of a packed tower, represented in FIG. l by the tower portion 26 and packing 29 of the decomposer 20,1the presentinvention may be practiced with any suitable gas-liquid contacting device, such as a splash condenser, tray column, `spray tower,'or wetted VWall column, i.e. any suitable means providing an extended gas-liquid contact surface area; vor the gas-liquid contact may be effected in a jet pump in which the monochloride-containing gas from the converter is simultaneously decomposed and compressed for recirculation to the converter lt). Also, while specific reference has been made to a mixture of aluminum trichloride'and sodium chloride as the molten salt used as the heat exchange medium in the decomposer, it will be appreciated that other molten salt mixtures, incorporating a substantial proportion of :aluminum trichloride together with other alkali metal chloride-s or alkaline earth metal chlorides, may equally be used, as indicated above.

More generally, it will be appreciated that the present invention in its broader aspects is not limited to use with subhalide distillation systems employing aluminum 'trichloride; and involving the synthesis of aluminum monochloride, but may be adapted for use with other -aluminum subhalide distillation operations to elect the-decom-y position of aluminum Vsubhalides other than aluminum monochloride. Byk Way of example, in one lalternative form of subhalide distillation operation the crude alloy or other impure aluminum-bearingV material to be rened is exposed to an upward flow of aluminum tribromide gas (ie. AlBrs), in a suitable converter such as the converter 10 in the system illustrated, under the elevated temperature conditions described above. Aluminum in the alloy reacts with the tribromide gas to form aluminum monobromide (ie. AlBr) which is withdrawn from the kconverter together with unreacted trib-rornide gas. In accordance with the present invetion this monobromidelcontainbromide together with other salt or salts, e.g. such as alkali metal bromides or alkaline earth metal bromides.

Y The heat exchange eiected in the decomposer between this' tribromide-containing molten salt mixture .and the monobromide-containing gas from the converter may bey such, if desired, as to evaporate some tribromide from the salt mixture; the resultant tribromide gas may be dis-y charge-d together with the tribromide gas otherwise pro duced in or introduced to the decomposer through the conduit 39 whilev the molten aluminum product andtribromide-lean molten salt mixture are separately-withdrawn through outlets 35` and 37 respectively. Tribromide may be restored to the salt mixture in a condenser such:

as the absorber vessel 42,01? the system illustrated, i.e. by

Adiverting a portion of thetribrornide gas withdrawn from ythe decomposer to such vessel and effectingY condensation of the tribrmodie gas in the molten salt mixture therein@ In other words, the operation of the apparatus illustrated and the performance of the .process of the present inven- 'tion in an aluminum subhalide distillation system employing tribromide rather than trichloride and involving above. In such case, of course, they moltengsaltwill collect in a pool at the lower end of the decomposing region, and the: molten aluminum will float thereon;-the molten aluminum may bey withdrawn through a product discharge outle'tsuitably positioned in the wall of the sump 21 and the molten salt may be withdrawn, eg. :through a conduit opening at the bottom of the sump. An exampleofsuch a salt mixture (believed tobe especiallysuitable foriuse.

in the decomposition of aluminum'rnonobr'omide referred to above) is va molten mixture of barium bromide and aluminum tribromide.` v i l ,In general, the'molten salt composition isv composed of material of the category of aluminum halides, andvof other metal salts, e.g.'halides, which are stable :at the temperatureslinvolved andin the presence ,-of the .aluminum salts and metallic aluminum, the composition being chosen to have a melting point below thatof aluminum and the `composition: alsoy preferably ybeing such .that it retains a substantial portion of itsintegrity as a molten material at the temperatures for subhalide decomposition, i.e. in that evaporation of any. part may be in :eifect controlled or limited so as to maintain ,at least some quantity of salt'for the desired heat removing yfunctionV throughout the decomposingl region. -ln particular, fas explained above,v exceptionally use'iulzk compositionsV are. selected from the: class consisting of aluminum halidesand halides of alkali metals and 'alkaline earth metals (including magnesium, as has been noted). x

As will be apparent, themolten saltenteringthezdecomposer should havea temperature Well'below. (and preferably very substantially below) the point at which decomposition of the incoming monochloride or other subhalide will begin. Ordinarily, becauseofconsideraf tions of economy, ,the `basic process conditions are selected so that the subhalide-containing gas reachesV the decomposery at a temperature fonly slightly .above the i,

temperature at which decomposition commences'. Decomposition, of course, occurs'at all temperatures lower than the last-mentioned value, which'(as indicated) is usuallyjusty belowthat of the gas leavingfthe converter or in every case isiy readily ascertainable vfrom the .conditions of conversion and of gas delivery from Vthe-converter. In any event, it will beiunderstood that the selection of a suitable temperature for the incoming moltenl salt mixture 4will ordinarily have no close relation to the upper limit:of=the decompositionrange, but.will prefer` `ably be effected at a far lower point which can be easily chosen for any given converter conditions, i.e. as explained hereinabove (in theV light of readily" determinable -heat-z removal requirements and with theiaid of simple tests if necessary), so,` that there is satisfactory,='complete de# composition of subhalide` in the `received gas andultimate .collection ofaluminum-metal ink molten form.`

It is` to be understood that the invention is not limited to the specieprocedures and embodiments herein Vshown and described, but maybe carried ,out in othei waysy withoutdeparture from its spirit. i

1. fA methodagof recovering metallic aluminum'from aluminum subhalide gas,comprising establishing a circulating ilow :of molten salt at Va ysubhalide-decomposing temperature while exposing saidsalt for contactwith gas at a first locality in said circulating ow, and conducting the subhalide gas into heat-exchange; ,contact `with said exposed molten salti atsaidvfirst locality to reduce Vthe temperature ofl said gas for decompositiongthereof to .yield aluminum metal andnormal aluminum-halide gas,A

13 while transferring `said .molten salt from said first locaiity to a second locality in said circulating fiow and removing heat from said molten salt at said second locality.

2. A method according to claim 1, wherein said molten salt is moved countercurrent to the subhalide gas and carries the produced aluminum from said first locality for collection of said aluminum as a body of molten metal.

3. A method of recovering metallic aluminum from aluminum subhalide gas, comprising establishing a circulating flow of molten halide salt at a subhalide-decomposing temperature through a confined region while exposing said salt for contact with gas at a first locality in said circulating flow Within said region, conducting the subhalide gas into heat-exchange contact with said exposed molten salt at said first locality to reduce the temperature of said gas for decomposition thereof to yield aluminum metal and normal aluminum halide gas, collecting said aluminum metal in a molten-body at a lower portion of said confined region, conducting said molten salt from said first locality through said lower portion of said confined region, as a discrete molten body, to a second locality in said circulating flow, and removing heat from said molten salt at said second locality.

4. A method of recovering metallic aluminum from aluminum subhalide gas, comprising establishing a circulating fiow of molten salt mixture containing normal aluminum halide, at a subhalide-decomposing temperature, through a confined region while exposing said molten mixture for contact with gas at a first locality in said circulating fiow within said reg-ion, and conducting the subhalide gas into heat-exchange contact with said exposed 4mixture at said first locality to reduce the temperature of said subhalide gas for decomposition thereof to yield aluminum metal and normal aluminum halide gas, whereby said mixture is heated and normal aluminum halide is evaporated therefrom, while transferring said molten mixture from said first locality to a second locality in said circulating fiow and removing heat from said molten mixture at said second locality, and while supplying normal aluminum halide to said mixture at a locality in said flow external to said confined region.

5. A method according to claim 4, wherein said step of supplying normal aluminum halide to said mixture comprises conducting normal aluminum halide gas from said confined region into contact with said flow of mixture as second in said cooling locality and condensing said normal aluminum halide gas in said mixture.

6. A method of recovering metallic aluminum from `aluminum subhalide gas, comprising establishing a circulating flow of molten mixture of halide salts containing normal aluminum halide, at a subhalide-decomposing temperature, through a confined region while exposing said molten mixture for contact with gas at a first locality in said circulating flow within said region, conducting the subhalide gas into heat-exchange contact with said exposed -mixture at said first locality to reduce the temperature of said subhalide gas for decomposition thereof to yield aluminum metal and normal aluminum halide gas, whereby said mixture is heated and normal aluminum halide is evaporated therefrom, collecting said aluminum metal in a molten body at a lower portion of said confined region, conducting said molten mixture from said first locality through said lower portion of said confined region, as a discrete mol-ten body, to a second locality in said circulating fiow, removing heat from said molten mixture at said second locality, .conducting normal aluminum halide gas from said confined region into contact with said fiow rof mixture at a locality external to said confined region, and condensing said normal aluminum halide gas in said mixture at said last-mentioned locality.

'7. A method according to claim 6, wherein said mixture has a lower specific gravity than molten aluminum.

8. A method according to claim 6, wherein said mixture has a higher specific gravity than molten aluminum.

9. A method of recovering metallic aluminum from aluminum monochloride gas, comprising establishing a circulating flow of molten chloride salt mixture including aluminum trichloride as a constituent thereof, at a monochloride-decomposing temperature, through a confined region while exposing said molten mixture for contact with gas at a first locality in said circulating fiow within said region, and conducting the mono-chloride gas into heat-exchange contact with said exposed mixture at said first locality to reduce the temperature of said monochloride gas for decomposition thereof to yield aluminum metal and aluminum trichloride gas, while transferring said molten mixture from said first locality to a second locality in said circulating flow and removing heat from said mixture at said second locality.

lli. A method according to claim 9, wherein said mixture has a lower specific gravity than molten aluminum, and including the steps of collecting said aluminum metal in a molten lbody at a lower portion of said confined region and conducting said molten mixture from said rst locality through said lower portion of said confined region, as a discrete molten body fioating on said molten aluminum body, to said second locality in said circulating flow.

11. A method according to claim 9, wherein said molten salt mixture comprises a molten mixture of aluminum trichloride and sodium chloride.

12. A method of recovering metallic aluminum from aluminum monochloride gas, comprising establishing a circulating flow of molten mixture of halide salts including aluminum trichloride as a constituent thereof, at a monochloride-decompsing temperature, through a confined region while exposing said molten mixture for contact with gas at a first locality in said circulating flow within said region, and conducting the monochl-oride gas into heat-exchange contact with said exposed mixture at said rst locality to reduce the temperature of said monochloride gas for decomposition thereof to yield aluminum metal and aluminum trichloride gas, whereby said mixture is heated and aluminum trichloride is evaporated therefrom, while transferring said molten mixture from said first locality to a second locality in said circulating fiow and removing heat from said molten mixture at said second locality, and conducting aluminum trichloride gas from said confined region into contact with said flow of mixture at a locality external to said confined region and condensing said trichloride gas in said mixture at said last-mentioned locality.

13. A method of recovering metallic alum'mum from aluminum monochloride gas, comprising establishing a circulating flow of molten salt mixture including aluminum trichloride as a constituent thereof, and having a sepcific gravity lower than molten aluminum, through a confined region while exposing -said molten mixtu-re for contact with gas at -a first locality in said circulating flow within said region, the remainder of said mixture being of the class of chloride salts of metals selected from the group consisting of alkali and alkaline earth metals, said mixture being circulated through said region kat a monochloride-decomposing temperature, conducting the monochloride gas into heat-exchange contact with said exposed mixture at said .first locality to reduce the temperature of said monochloride gas for decomposition thereof to yield aluminum metal and 'aluminum trichloride gas, whereby said mixture is heated and aluminum trichloride is evaporated therefrom, withdrawing aluminum trichloride gas from said confined region, collecting said aluminum metal in a molten body at a lower portion of said confined region, conducting said molten mixture from said first locality through said lower portion of said confined region, as a discrete molten body iioating on said molten aluminum body, to a second locality in said circulating flow, removing heat from said molten mixture at said second locality, conducting aluminum trichloride gas from said confined i region into contact with said ow of mixture at a locality external to said confined region, and condensing said trichloride gas in Ysaid mixture at said last-mentioned locality.

14. A method according to claim 13, wherein gaseous impurities carried with said aluminum trichloride gas to said last-mentioned locality are separated from said trichloride gas as said trichloride gas condenses in said last-mentioned locality.

15. A method of recovering metallic aluminum from aluminum monochloride gas discharged from a converting region of an aluminum subhalide distillation system, comprising establishing a circulating ow of a molten salt mixture including aluminum trichloridev as a constituent thereof, and having a specified gravity lower than molten aluminum, through a confined region while -exposing said molten mixture for contact with gas at a first locality in said circulating flow within said region, the remainder of said mixture being of the class of halide salts of metals selected from the group consisting of alkali and Valkaline-earth metal, said mixturefbeing circulated through said region f at a monochloridedecomposing temperature, conducting the monochloride `gas through said iirst locality in said confined region in a direction countercurrent to said flow of moltenfsalt mixture and in heat-exchange contact with said exposed mixtureover an extended contact surface area therein to reduce the temperature of said monochloride gas for decomposition thereof to yield aluminum metal and aluminum trichloride gas, withdrawing aluminum trichloride gas from said confined region, collecting aluminum metal in a molten body at a lowerportion of said confined region, conducting said molten mixture from said first locality through said lower portion ,of

said confined region, as a discrete molten body floating on said molten aluminum body, to a second locality in said circulating flow external to said confined region and removing heat from said mixture at said second locality.

16. A method according to claim 15, wherein the flow of molten s alt mixture is introduced to the confined region at a temperature ofA kabout 675 C., the monochloride gas is introduced thereto at a temperature above packing of elements supported on said perforate memberk and a sump portion below said perforate member. adapted to lcontain bodiesy of liquid, gas inlet means for introducing subhalide gas to an upper locality in saidV sump` portion lbelow said perforate member, salt inlet 'means for introducing a downwardly directed flow of molten salt to said tower chamber above said packing, first outlet conduit means for withdrawing-normal aluminumhalide gas from said tower chamber above said packing, second outlet conduit means for withdrawing molten aluminum metal from a bodyE thereof at the lowerV extremity of said sump portionfthird outlet conduit means at a level of -said sump portion above said secondv outlet conduit means, for separately withdrawing molten Salt 15 from a body thereof iioating on said-bodylof molten aluminum virr said sump portion, .a `condenser including a vessely disposed and adapted Ito receive moltensalt from said third outlet conduit-means, conduit means for conveying toY said vessel a `rpreselected proportion of the normal aluminum halide gas withdrawn from said chamber through said i'rst'outlet conduit means, cooling means for removing heatfrom said molten salt'in said vessel, means for effecting intimate contact between molten salt? and normalV aluminum halide gas in said vessel, means for discharging ,gas from said vessel, and means for recircuiating molten salti from ;Said vessel through said said inletmeans to said tower chamber. Y 18.Apparatus for ,decomposing 4aluminum subhalide gas, comprising, in combination, means dening a closed decomposing chamber, gas inlet. means for introducing subhalide gas to said decomposing chamber, salt inlet means for introducing moltensalt to` said `decomposing chamber at anV upper region thereof, means.` in said de-V composing chamber for distributing said molten salt to provide an 'extended rgas-liquid contact surface therein, said gas,- inletV means,` said ,saltinlet means, rand said molten salt Vdistributing meansbeing Timutually arranged to vpromote intimate `heat-exchangesy contact between said molten salt and said subhalide sgas in said decomposingV chamber, first outlet conduit means Vfor WithdraWing/ normal aluminum 'halide .gas `from-said decomposing chamber,- second outlet-conduit meansat a lower ,levelv for withdrawing molten aluminum metal fromy a lower 'portionrot' saiddecomposing chamber, third outlet conduit means at a diiierent lower level-for separately with@ drawing molten salt from another lowerportion of said decomposing chamber, means for recycling Ymolten 'saltf from said third outlet-conduit means through said salt,

inletk means -to said decomposing chamber, means as-, sociated withisaid recycling fm'eans and defining a con-l densing chamber, vforreceiving molten salt fromthe third outlet conduit means, meansfor-,coolin-g-the molten salt advanced from said third outlet conduit means to said 'condensing chamber, means having connection ywith the first outlet conduit means, forintroducing to said condensing chamber normal aluminum halide gas withdrawn from said decomposingchamber, and meansfor promoting intimate contact between saidnormal aluminum vhalide gasV and said kmolten saltvin` said condensing chamber, for absorption of normal halide gas in said molten salt.

References Cited bythe Examinen i UNITEDSTATES rPATENTSv 2,255,549 9/1941 Kruh 75-'68 2,876,045 A5/1945 Gaither,A 23-294 `2,387,228 10/1945 Arnold 234493 2,462,661 2/1949 Munday 754-68 2,470,305 5/1949 Gross 75-68 2,621,120 12/ 1952 Pederson 75-68 2,622,019 12/,1952 Scheuer 75-68 2,758,023 *t5/1956, Bareis 75-63 2,760,858, 8/19564 Findlay, 75--84.5 2,914,398 11/1959 AJohnston 75-68 3,078,159k 2/1963j` Hollingshead ,75-,68

FOREIGN PATENTS 635,318 4/1950 Grea'tBritain.'`

DAVID L: RECK, Primary Examiner.

BENJAMrN HENKIN, i Examiner. 

1. A METHOD OF RECOVERING METALLIC ALUMINUM FROM ALUMINUM SUBHALIDE GAS, COMPRISING ESTABLISHING A CIRCULATING FLOW OF MOLTEN SALT AT A SUBHALIDE-DECOMPOSING TEMPERATURE WHILE EXPOSING SAID SALT FOR CONTACT WITH GAS AT A FIRST LOCALLY IN SAID CIRCULATING FLOW, AND CONDUCTING, THE SUBHALIDE GAS INTO HEAT-EXCHANGE CONTACT WITH SAID EXPOSED MOLTEN SALT AT SAID FIRST LOCALITY TO REDUCE THE TEMPERATURE OF SAID GAS FOR DECOMPOSITION THEREOF TO YIELD ALUMINUM METAL AND NORMAL ALUMINUM HALIDE GAS, WHILE TRANSFERRING SAID MOLTEN SALT FROM SAID FIRST LOCALITY TO A SECOND LOCALITY IN SAID CIRCULATING FLOW AND 